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US9982159B2 - Paint composition and method for forming multi-layered coating film - Google Patents

Paint composition and method for forming multi-layered coating film Download PDF

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Publication number
US9982159B2
US9982159B2 US14/438,349 US201314438349A US9982159B2 US 9982159 B2 US9982159 B2 US 9982159B2 US 201314438349 A US201314438349 A US 201314438349A US 9982159 B2 US9982159 B2 US 9982159B2
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Prior art keywords
coating film
coating composition
acid
parts
aqueous
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US14/438,349
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US20150284585A1 (en
Inventor
Kohei Onishi
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Kansai Paint Co Ltd
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Kansai Paint Co Ltd
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Assigned to KANSAI PAINT CO., LTD. reassignment KANSAI PAINT CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ONISHI, KOHEI
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
    • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
    • C08F220/10—Esters
    • C08F220/12—Esters of monohydric alcohols or phenols
    • C08F220/16—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms
    • C08F220/18—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms with acrylic or methacrylic acids
    • C08F220/1804—C4-(meth)acrylate, e.g. butyl (meth)acrylate, isobutyl (meth)acrylate or tert-butyl (meth)acrylate
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D133/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
    • C09D133/04—Homopolymers or copolymers of esters
    • C09D133/14—Homopolymers or copolymers of esters of esters containing halogen, nitrogen, sulfur or oxygen atoms in addition to the carboxy oxygen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/14—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
    • B05D7/148—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies using epoxy-polyolefin systems in mono- or multilayers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/56—Three layers or more
    • B05D7/57—Three layers or more the last layer being a clear coat
    • B05D7/572—Three layers or more the last layer being a clear coat all layers being cured or baked together
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
    • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
    • C08F220/04—Acids; Metal salts or ammonium salts thereof
    • C08F220/06—Acrylic acid; Methacrylic acid; Metal salts or ammonium salts thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
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    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
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    • C08F220/10—Esters
    • C08F220/20—Esters of polyhydric alcohols or phenols, e.g. 2-hydroxyethyl (meth)acrylate or glycerol mono-(meth)acrylate
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    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
    • C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
    • C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/16—Nitrogen-containing compounds
    • C08K5/17—Amines; Quaternary ammonium compounds
    • C08K5/19—Quaternary ammonium compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/16—Nitrogen-containing compounds
    • C08K5/34—Heterocyclic compounds having nitrogen in the ring
    • C08K5/3412—Heterocyclic compounds having nitrogen in the ring having one nitrogen atom in the ring
    • C08K5/3432—Six-membered rings
    • C08K5/3435—Piperidines
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/16—Nitrogen-containing compounds
    • C08K5/34—Heterocyclic compounds having nitrogen in the ring
    • C08K5/3467—Heterocyclic compounds having nitrogen in the ring having more than two nitrogen atoms in the ring
    • C08K5/3472—Five-membered rings
    • C08K5/3475—Five-membered rings condensed with carbocyclic rings
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/54—Silicon-containing compounds
    • C08K5/541—Silicon-containing compounds containing oxygen
    • C08K5/5415—Silicon-containing compounds containing oxygen containing at least one Si—O bond
    • C08K5/5419—Silicon-containing compounds containing oxygen containing at least one Si—O bond containing at least one Si—C bond
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D133/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
    • C09D133/02—Homopolymers or copolymers of acids; Metal or ammonium salts thereof
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D133/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
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    • C09D133/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical
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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D163/00—Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D169/00—Coating compositions based on polycarbonates; Coating compositions based on derivatives of polycarbonates
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D17/00—Pigment pastes, e.g. for mixing in paints
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D171/00—Coating compositions based on polyethers obtained by reactions forming an ether link in the main chain; Coating compositions based on derivatives of such polymers
    • C09D171/02—Polyalkylene oxides
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
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    • C09D7/40—Additives
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
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    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J133/00—Adhesives based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Adhesives based on derivatives of such polymers
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    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
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Definitions

  • the present invention relates to a coating composition and a method for forming a multilayer coating film using the coating composition.
  • the 3-coat 2-bake process comprises the following steps in order: after subjecting a substrate to electrodeposition coating and curing by heating, application of an intermediate coating composition ⁇ curing by heating ⁇ application of a base coating composition ⁇ preheating (preliminary heating) ⁇ application of a clear coating composition ⁇ curing by heating.
  • the 2-coat 2-bake process comprises the following steps in order: after subjecting a substrate to electrodeposition coating and curing by heating, application of an intermediate coating composition ⁇ curing by heating ⁇ application of a top coating composition ⁇ curing by heating.
  • the 3-coat 2-bake process is used for forming a coating film of a so-called metallic color by using a base coating composition comprising an effect pigment
  • the 2-coat 2-bake process is used for forming a coating film of a so-called solid color, such as white or black, by using a top coating composition comprising a color pigment.
  • Patent Literature 1 discloses a method for forming a multilayer coating film that employs a coating process for forming a multilayer coating film by a 3-coat 1-bake process using an aqueous intermediate coating composition, an aqueous base coating composition, and a clear coating composition, wherein a specific aqueous base coating composition is applied to an intermediate coating film that has been adjusted to have a specific solids content, the resulting base coating film is adjusted to have a specific solids content, a clear coating composition containing a carboxy-containing compound and a polyepoxide is applied thereto, and the intermediate coating film, the base coating film, and the clear coating film are cured all at once under specific heating conditions.
  • the multilayer coating film obtained by this coating film-forming method may have insufficient smoothness and distinctness of image.
  • Patent Literature 2 discloses a method for forming a multilayer coating film that employs a 3-coat 1-bake process comprising sequentially applying an aqueous first colored coating composition, an aqueous second colored coating composition, and a clear coating composition to a substrate, and simultaneously heat-curing the resulting three layers of the multilayer coating film, wherein an aqueous first colored coating composition (X) comprises an acrylic resin (A), a curing agent (B), and a urethane resin emulsion (C), and a first colored coating film formed from the aqueous first colored coating composition (X) has a water swelling rate of 100% or less and an organic solvent swelling rate of 300% or less before a second base is applied.
  • the multilayer coating film obtained by this coating film-forming method may have insufficient smoothness and distinctness of image.
  • Patent Literature 3 discloses an aqueous coating composition comprising an acrylic resin (A), a curing agent (B), and a urethane resin emulsion (C), the urethane resin emulsion being prepared using constituent components comprising a polyisocyanate component that contains an alicyclic diisocyanate, and a polycarbonate diol component obtained from a diol component that contains a cycloalkylene group-containing alicyclic diol having 6 or more carbon atoms.
  • Patent Literature 3 also discloses a method for forming a multilayer coating film that employs a 3-coat 1-bake process comprising sequentially applying an aqueous first colored coating composition, an aqueous second colored coating composition, and a clear coating composition to a substrate, and simultaneously heat-curing the resulting three layers of the multilayer coating film, wherein the aforementioned aqueous coating composition is used as the aqueous first colored coating composition.
  • Patent Literature 3 discloses, as a preferable embodiment of the aqueous first colored coating composition, a coating composition further comprising a specific oligomer.
  • the effect of improving the finished appearance in terms of smoothness, distinctness of image, etc. may be insufficient with this coating film-forming method.
  • Patent Literature 4 discloses a method for forming a multilayer coating film that employs a 3-coat 1-bake process comprising the step of simultaneously bake-curing an intermediate coating film, a base coating film, and a clear coating film, wherein an aqueous intermediate coating composition used for forming the intermediate coating film comprises a specific acrylic resin emulsion, a completely alkyl-etherified melamine resin, and a carbodiimide compound, and an aqueous base coating composition used for forming the base coating film comprises a specific acrylic resin emulsion and a specific polyether polyol.
  • this coating film-forming method prevention of a mixed layer between the intermediate coating film and the base coating film is attempted by suppressing the internal stress of the intermediate coating film.
  • the multilayer coating film obtained by this method may have an insufficient finished appearance.
  • An object of the present invention is to provide a clear coating composition that makes it possible to form a multilayer coating film that is less susceptible to the surface roughness of a substrate, has excellent concealment of the surface state (i.e., irreguralities) of the substrate, and exhibits excellent smoothness, distinctness of image, and weatherability, when an aqueous first colored coating composition, an aqueous second colored coating composition, and the clear coating composition are sequentially applied to the substrate, and the resulting coating films are cured all at once to form the multilayer coating film; and a method for forming a multilayer coating film using the clear coating composition.
  • the present inventor conducted extensive research to achieve the above object and found that in a coating process for forming a multilayer coating film by a 3-coat 1-bake process, incorporation of a specific polyol in a clear coating composition is highly effective to improve concealment of the surface state (i.e., irreguralities) of a substrate, and when a coating composition comprising a carboxy-containing compound (A), a polyepoxide (B), and a specific polyol (C) is used as a clear coating composition, the above object can be achieved.
  • the present invention has been accomplished based on these findings.
  • the present invention provides a coating composition used as a clear coating composition (Z) in a method for forming a multilayer coating film, the method comprising sequentially performing the following steps (1) to (4) on a substrate:
  • the coating composition comprising a carboxy-containing compound (A), a polyepoxide (B), and a polyol (C) having a number average molecular weight of 300 to 1,500, the polyol (C) being at least one member selected from the group consisting of polyoxyalkylene-containing polyols (C1) and polycarbonate polyols (C2).
  • the present invention provides a method for forming a multilayer coating film, the method comprising performing the following steps (1) to (4) on a substrate:
  • the present invention provides an article coated by the aforementioned method for forming a multilayer coating film.
  • the polyol in the coating composition of the present invention has a low molecular weight, thermal flowability in the curing process for a multilayer coating film can be improved, and concealment of a substrate is enhanced, thus effectively reducing the influence of the surface state (i.e., irreguralities) of the substrate, which causes an impaired finished appearance; therefore, a multilayer coating film with excellent finished appearance in terms of smoothness, distinctness of image, etc., can be provided by a 3-coat 1-bake process.
  • the polyol has hydroxy groups, which are crosslinkable functional groups, and has excellent reactivity.
  • the polyol is also preferable from the viewpoint of coating film performance in terms of weatherability, etc.
  • the coating film performance can be further enhanced by, for example, a preferable embodiment in which the hydroxy value of the base resin is improved.
  • the coating composition of the present invention enables a multilayer coating film with excellent smoothness and distinctness of image as well as excellent weatherability to be formed in a coating film-forming method that employs a 3-coat 1-bake process, since excellent concealment of the surface state (i.e., irreguralities) of the substrate is imparted.
  • the coating composition of the present invention (which, hereafter, may be referred to as the “present coating composition”) is a coating composition for use as a clear coating composition (Z) in a method for forming a multilayer coating film, the method comprising sequentially performing the following steps (1) to (4) on a substrate:
  • the coating composition comprising a carboxy-containing compound (A), a polyepoxide (B), and a polyol (C) having a number average molecular weight of 300 to 1,500, the polyol (C) being at least one member selected from the group consisting of polyoxyalkylene-containing polyols (C1) and polycarbonate polyols (C2).
  • Coating Composition of the Present Invention Carboxy-Containing Compound (A)
  • the carboxy-containing compound (A) contains carboxy groups in the molecule and has an acid value of typically 50 to 500 mg KOH/g, and preferably 80 to 300 mg KOH/g.
  • Examples of the carboxy-containing compound (A) include the following polymers (1) to (3) and compound (4).
  • the polymers (1) to (3) and compound (4) may be used singly or in a combination.
  • Polymer (1) Polymer Containing Half-Esterified Acid Anhydride Groups in the Molecule
  • half-esterified acid anhydride group means a group comprising carboxy and carboxylate groups, which is obtained by adding an aliphatic monohydric alcohol to an acid anhydride group to perform ring opening (i.e., half-esterification).
  • half-esterified acid anhydride group may be referred to simply as a “half ester group.”
  • the polymer (1) can be easily obtained by, for example, copolymerizing a half ester group-containing unsaturated monomer with one or more other polymerizable unsaturated monomers by a usual method.
  • the polymer (1) can also be easily obtained by carrying out copolymerization in a similar manner using an acid anhydride group-containing unsaturated monomer in place of the half ester group-containing unsaturated monomer, and then half-esterifying the acid anhydride group.
  • Examples of acid anhydride group-containing unsaturated monomers include maleic anhydride, itaconic anhydride, and the like.
  • Examples of half ester group-containing unsaturated monomers include those obtained by half-esterifying acid anhydride groups of acid anhydride group-containing unsaturated monomers. As mentioned above, the half-esterification can be carried out either before or after the copolymerization reaction.
  • aliphatic monohydric alcohols examples include low-molecular-weight monohydric alcohols, such as methanol, ethanol, isopropanol, n-butanol, isobutanol, tert-butanol, ethylene glycol monomethyl ether, and ethylene glycol monoethyl ether.
  • the half-esterification can be carried out by a usual method, for example, at a temperature of room temperature to about 80° C., using, if necessary, a tertiary amine as a catalyst.
  • Examples of other polymerizable unsaturated monomers include hydroxy-containing unsaturated monomers, (meth)acrylic acid esters, vinyl ethers or allyl ethers, olefinic compounds and diene compounds, hydrocarbon ring-containing unsaturated monomers, nitrogen-containing unsaturated monomers, hydrolyzable alkoxysilyl group-containing acrylic monomers, and the like.
  • (meth)acrylate is a general term for acrylate and methacrylate
  • (meth)acrylic acid is a general term for acrylic acid and methacrylic acid.
  • hydroxy-containing unsaturated monomers include C 2-8 hydroxyalkyl esters of acrylic or methacrylic acid, such as 2-hydroxyethyl (meth)acrylate, 3-hydroxypropyl(meth)acrylate, and hydroxybutyl (meth)acrylate; monoesters of polyether polyols, such as polyethylene glycol, polypropylene glycol, and polybutylene glycol, with unsaturated carboxylic acids, such as (meth)acrylic acid; monoethers of polyether polyols, such as polyethylene glycol, polypropylene glycol, and polybutylene glycol, with (meth)acrylic acid hydroxyalkyl esters, such as 2-hydroxyethyl (meth)acrylate; monoesterification products or diesterification products of acid anhydride group-containing unsaturated compounds, such as maleic anhydride and itaconic anhydride, with glycols, such as ethylene glycol, 1,6-hexanediol, and neopen
  • Examples of (meth)acrylic acid esters include C 1-24 alkyl esters or cycloalkyl esters of acrylic or methacrylic acid, such as methyl acrylate, ethyl acrylate, propyl acrylate, isopropyl acrylate, n-butyl acrylate, isobutyl acrylate, tert-butyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, n-octyl acrylate, decyl acrylate, lauryl acrylate, stearyl acrylate, cyclohexyl acrylate, methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, tert-butyl methacrylate, hexyl methacrylate, 2-ethy
  • vinyl ethers or allyl ethers examples include ethyl vinyl ether, n-propyl vinyl ether, isopropyl vinyl ether, butyl vinyl ether, tert-butyl vinyl ether, pentyl vinyl ether, hexyl vinyl ether, octyl vinyl ether, and like chain-like alkyl vinyl ethers; cyclopentyl vinyl ether, cyclohexyl vinyl ether, and like cycloalkyl vinyl ethers; phenyl vinyl ether, trivinyl benzyl ether, and like aryl vinyl ethers; benzyl vinyl ether, phenethyl vinyl ether, and like aralkyl vinyl ethers; allyl ethyl ether and like allyl ethers; and the like.
  • olefinic compounds and diene compounds examples include ethylene, propylene, butylene, vinyl chloride, butadiene, isoprene, chloroprene, and the like.
  • hydrocarbon ring-containing unsaturated monomers examples include styrene, ⁇ -methylstyrene, phenyl (meth)acrylate, phenylethyl (meth)acrylate, phenylpropyl (meth)acrylate, benzyl (meth)acrylate, phenoxyethyl (meth)acrylate, cyclohexyl (meth)acrylate, 2-acryloyloxyethylhydrogen phthalate, 2-acryloyloxypropylhydrogen phthalate, 2-acryloyloxypropylhexahydrohydrogen phthalate, 2-acryloyloxypropyltetrahydrohydrogen phthalate, ester of p-tert-butyl-benzoic acid with hydroxyethyl (meth)acrylate, dicyclopentenyl (meth)acrylate, and the like.
  • nitrogen-containing unsaturated monomers include N,N-dimethylaminoethyl (meth)acrylate, N,N-diethylaminoethyl (meth)acrylate, N-t-butylaminoethyl (meth)acrylate, and like nitrogen-containing alkyl (meth)acrylates; acrylamide, methacrylamide, N-methyl (meth)acrylamide, N-ethyl (meth)acrylamide, N,N-dimethyl (meth)acrylamide, N,N-dimethylaminopropyl(meth)acrylamide, N,N-dimethylaminoethyl (meth)acrylamide, and like polymerizable amides; 2-vinylpyridine, 1-vinyl-2-pyrrolidone, 4-vinylpyridine, and like aromatic nitrogen-containing monomers; acrylonitrile, methacrylonitrile, and like polymerizable nitriles; allylamines; and the like.
  • hydrolyzable alkoxysilyl group-containing acrylic monomers examples include ⁇ -(meth)acryloyloxypropyltrimethoxysilane, ⁇ -(meth)acryloyloxypropylmethyldimethoxysilane, ⁇ -(meth)acryloyloxyethyltrimethoxysilane, ⁇ -(meth)acryloyloxypropyltriethoxysilane, ⁇ -(meth)acryloyloxypropylmethyldiethoxysilane, and the like.
  • the copolymerization of a half ester group- or acid anhydride group-containing unsaturated monomer with one or more other polymerizable unsaturated monomers can be carried out by a generally employed method for polymerization of unsaturated monomers. Considering the versatility, cost, etc., solution radical polymerization in an organic solvent is the most suitable. A desired polymer can be easily obtained by carrying out a copolymerization reaction at a temperature of about 60 to about 150° C. in a solvent in the presence of a polymerization initiator.
  • solvents examples include xylene, toluene, and like aromatic solvents; methyl ethyl ketone, methyl isobutyl ketone, and like ketone solvents; ethyl acetate, butyl acetate, isobutyl acetate, 3-methoxy butyl acetate, and like ester solvents; n-butanol, isopropyl alcohol, and like alcohol solvents; and the like.
  • polymerization initiators include azo catalysts, peroxide catalysts, and the like.
  • the suitable proportions of the half ester group- or acid anhydride group-containing unsaturated monomer and the one or more other polymerizable unsaturated monomers used in the copolymerization, based on the total mass of monomers used, are usually as follows: the proportion of the half ester group- or acid anhydride group-containing unsaturated monomer is within the range of generally 10 to 50 mass %, and preferably 20 to 40 mass %, in view of curability, storage stability, etc.; the proportion of the one or more other polymerizable unsaturated monomers is within the range of generally 50 to 90 mass %, and preferably 60 to 80 mass %.
  • styrene is used suitably in a proportion of up to about 35 mass % in view of the weatherability of the cured coating film.
  • the polymer (1) is preferably an acrylic polymer having a number average molecular weight of 1,000 to 20,000, and particularly 1,500 to 15,000. If the number average molecular weight of the polymer is less than 1,000, the weatherability of the cured coating film tends to be impaired; whereas if the number average molecular weight exceeds 20,000, the compatibility with the polyepoxide tends to be reduced.
  • the number average molecular weight and the weight average molecular weight are determined by measuring the retention time (retention volume) using Gel Permeation Chromatography (GPC), and converting the values into those of polystyrene using the retention time (retention volume) of the standard polystyrene, whose molecular weight is known, measured under the same conditions.
  • GPC Gel Permeation Chromatography
  • the number average molecular weight and the weight average molecular weight can be measured using an HLC8120GPC gel permeation chromatography apparatus (trade name; produced by Tosoh Corporation) together with four columns “TSKgel G-4000HXL,” “TSKgel G-3000HXL,” “TSKgel G-2500HXL,” and “TSKgel G-2000HXL” (trade names; all produced by Tosoh Corporation), and a differential refractometer as a detector under the following conditions: mobile phase, tetrahydrofuran; measurement temperature, 40° C.; and flow rate, 1 mL/min.
  • Polymer (2) Polymer Containing Carboxy Groups in the Molecule
  • the polymer (2) can be easily obtained by copolymerizing a carboxy-containing unsaturated monomer with one or more other polymerizable unsaturated monomers in the same manner as in the polymer (1).
  • carboxy-containing unsaturated monomers examples include acrylic acid, methacrylic acid, crotonic acid, itaconic acid, maleic acid, fumaric acid, 2-carboxyethyl (meth)acrylate, 3-carboxypropyl(meth)acrylate, 5-carboxypentyl(meth)acrylate, and the like.
  • examples of other polymerizable unsaturated monomers include those mentioned in the description of the polymer (1), such as (meth)acrylic acid esters, vinyl ethers or allyl ethers, olefinic compounds and diene compounds, hydrocarbon ring-containing unsaturated monomers, and nitrogen-containing unsaturated monomers.
  • the polymer (2) has a number average molecular weight of typically 1,000 to 20,000, and particularly preferably 1,500 to 15,000, from the viewpoint of the weatherability of the cured coating film, compatibility with the polyepoxide (B), etc.
  • the carboxy-containing polyester polymer can be easily obtained by a condensation reaction of a polyhydric alcohol with a polycarboxylic acid.
  • polyhydric alcohols include ethylene glycol, butylene glycol, 1,6-hexanediol, trimethylolpropane, pentaerythritol, and the like.
  • polycarboxylic acids include adipic acid, terephthalic acid, isophthalic acid, phthalic anhydride, hexahydrophthalic anhydride, and the like.
  • the carboxy-containing polyester polymer can be obtained by a one-step reaction under such conditions that carboxy groups of the polycarboxylic acid are present in excess.
  • the carboxy-containing polyester polymer can be obtained by first synthesizing a hydroxy-terminated polyester polymer under such conditions that hydroxy groups of the polyhydric alcohol are present in excess, and thereafter adding an acid anhydride group-containing compound, such as phthalic anhydride, hexahydrophthalic anhydride, or succinic anhydride.
  • an acid anhydride group-containing compound such as phthalic anhydride, hexahydrophthalic anhydride, or succinic anhydride.
  • the carboxy-containing polyester polymer (3) has a number average molecular weight of typically 500 to 20,000, and particularly preferably 800 to 10,000.
  • the half ester can be obtained by reacting a polyol with a 1,2-acid anhydride under such conditions that a ring-opening reaction of the acid anhydride occurs, but a polyesterification reaction does not substantially occur.
  • the resulting reaction product generally has a low molecular weight and narrow molecular weight distribution. Further, the reaction product has a low volatile organic content when contained in a coating composition and imparts excellent acid resistance and other properties to the resulting coating film.
  • the half ester can be obtained by, for example, reacting a polyol and a 1,2-acid anhydride in an inert atmosphere, such as a nitrogen atmosphere, in the presence of a solvent.
  • a solvent such as a nitrogen atmosphere
  • preferred solvents include ketones, such as methyl amyl ketone, diisobutyl ketone, and methyl isobutyl ketone; aromatic hydrocarbons, such as toluene and xylene; and other organic solvents, such as dimethylformamide, and N-methylpyrrolidone.
  • the reaction is carried out preferably at a low temperature of about 150° C. or less. More specifically, it is preferred that the reaction temperature be typically about 70 to about 150° C., and particularly preferably about 90 to about 120° C. Basically, the reaction time slightly varies depending on the reaction temperature, but is typically about 10 minutes to about 24 hours.
  • the ratio of the acid anhydride/polyol in the reaction is such that the equivalent ratio of the acid anhydride/polyol is 0.8/1 to 1.2/1, when calculating the acid anhydride as a monofunctional compound. Thereby, the desired half ester can be obtained in the maximum yield.
  • the acid anhydride for use in the preparation of the desired half ester has 2 to 30 carbon atoms excluding the carbon atoms in the acid moiety.
  • acid anhydrides include aliphatic acid anhydrides, alicyclic acid anhydrides, olefin acid anhydrides, cyclic olefin acid anhydrides, and aromatic acid anhydrides.
  • These acid anhydrides may have one or more substituents insofar as the substituents do not adversely affect the reactivity of the acid anhydride or the properties of the resulting half ester. Examples of such substituents include chloro, alkyl, alkoxy, and the like.
  • acid anhydrides include succinic anhydride, methylsuccinic anhydride, dodecenylsuccinic anhydride, octadecenylsuccinic anhydride, phthalic anhydride, tetrahydrophthalic anhydride, methyltetrahydrophthalic anhydride, hexahydrophthalic anhydride, alkylhexahydrophthalic anhydride (such as methylhexahydrophthalic anhydride), tetrafluorophthalic anhydride, endomethylenetetrahydrophthalic anhydride, chlorendic anhydride, itaconic anhydride, citraconic anhydride, maleic anhydride, and the like.
  • polyols usable in the half-esterification of the acid anhydride include those having 2 to 20 carbon atoms, and particularly 2 to 10 carbon atoms.
  • Preferable examples include diols, triols, and mixtures thereof.
  • Specific examples include aliphatic polyols, such as ethylene glycol, 1,2-propanediol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, glycerol, 1,2,3-butane triol, 1,6-hexanediol, neopentyl glycol, diethylene glycol, dipropylene glycol, 1,4-cyclohexane dimethanol, 3-methyl-1,5-pentanediol, trimethylolpropane, 2,2,4-trimethylpentane-1,3-diol, pentaerythritol, and 1,2,3,4-butanetetraol.
  • the half ester has a number average molecular weight of typically 400 to 1,000, and particularly 500 to 900.
  • the half ester has high reactivity with epoxy and thus is useful in the preparation of coating compositions with a high solids content.
  • the carboxy-containing compound (A) is a polymer obtained by adding an aliphatic monohydric alcohol to a monomer mixture containing maleic anhydride or itaconic anhydride, and one or more other polymerizable unsaturated monomers selected from the group consisting of hydroxy-containing unsaturated monomers, (meth)acrylic acid esters, vinyl ethers, allyl ethers, olefinic compounds, diene compounds, hydrocarbon ring-containing unsaturated monomers, nitrogen-containing unsaturated monomers, and hydrolyzable alkoxysilyl group-containing acrylic monomers.
  • the one or more other polymerizable unsaturated monomers comprises a (meth)acrylic acid ester and a hydrocarbon ring-containing unsaturated monomer (in particular, styrene).
  • the polyepoxide (B) used in combination with the above-mentioned carboxy-containing compound (A) is a compound containing epoxy groups in the molecule.
  • the polyepoxide (B) is preferably a compound in which the epoxy group content is in the range of typically 0.8 to 10 mmol/g, and particularly 1.2 to 5.0 mmol/g.
  • polyepoxide (B) examples include epoxy-containing acrylic polymers; diglycidyl ether, 2-glycidylphenyl glycidyl ether, 2,6-diglycidylphenyl glycidyl ether and like glycidyl ether compounds; vinylcyclohexene dioxide, limonene dioxide and like glycidyl- or alicyclic epoxy-containing compounds; dicyclopentadiene dioxide, bis(2,3-epoxycyclopentyl)ether, epoxycyclohexenecarboxylic acid ethylene glycol diester, bis(3,4-epoxycyclohexyl methyl) adipate, 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexanecarboxylate, 3,4-epoxy-6-methylcyclohexylmethyl-3,4-epoxy-6-methylcyclohexane carboxylate and like alicyclic epoxy-containing compounds; and the
  • epoxy-containing acrylic polymers can be preferably used.
  • Such an epoxy-containing acrylic polymer has a number average molecular weight of preferably 1,000 to 20,000, and particularly preferably 1,500 to 15,000, from the viewpoint of coating film performance and finished appearance.
  • the epoxy-containing acrylic polymer can be easily obtained by copolymerizing an epoxy-containing unsaturated monomer and one or more other polymerizable unsaturated monomers in the same manner as in the polymer (1).
  • epoxy-containing unsaturated monomers examples include glycidyl (meth)acrylate, allyl glycidyl ether and like aliphatic epoxy-containing unsaturated monomers, and 3,4-epoxycyclohexylmethyl (meth)acrylate and like alicyclic epoxy-containing unsaturated monomers.
  • Examples of other polymerizable unsaturated monomers include those mentioned in the description of the polymer (1), such as hydroxy-containing unsaturated monomers, (meth)acrylic acid esters, vinyl ethers or allyl ethers, olefinic compounds and diene compounds, hydrocarbon ring-containing unsaturated monomers, nitrogen-containing unsaturated monomers, and hydrolyzable alkoxysilyl group-containing acrylic monomers.
  • hydroxy-containing unsaturated monomers are preferable from the viewpoint of coating film performance in terms of the weatherability, etc., of the clear coating film.
  • the hydroxy value is preferably 50 to 200 mg KOH/g, particularly preferably 80 to 150 mg KOH/g, and further particularly preferably 100 to 140 mg KOH/g, to achieve excellent coating film performance in terms of weatherability, etc., in addition to an excellent finished appearance of the clear coating film.
  • the ratio of the carboxy-containing compound (A) and polyepoxide (B) in the present coating composition is preferably such that the equivalent ratio of carboxy groups in the carboxy-containing compound (A) to epoxy groups in the polyepoxide (B) is generally 1/0.5 to 0.5/1, particularly 1/0.7 to 0.7/1, and further particularly 1/0.8 to 0.8/1.
  • the polyol (C) is at least one member selected from the group consisting of polyoxyalkylene-containing polyols (C1) and polycarbonate polyols (C2).
  • the polyol (C) has a number average molecular weight of 300 to 1,500, preferably 350 to 1,000, and more preferably 400 to 800.
  • the polyol (C) has a hydroxy value of preferably 60 to 400 mg KOH/g, more preferably 100 to 350 mg KOH/g, and particularly preferably 150 to 300 mg KOH/g.
  • polyoxyalkylene-containing polyols (C1) include compounds obtained by adding an alkylene oxide to an active hydrogen-containing compound, such as a polyhydric alcohol, a polyhydric phenol, or a polycarboxylic acid.
  • active hydrogen-containing compounds include water, polyhydric alcohols (ethylene glycol, diethylene glycol, trimethylene glycol, propylene glycol, 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, 1,4-dihydroxymethylcyclohexane, cyclohexylene glycol, and like dihydric alcohols; glycerin, trioxyisobutane, 1,2,3-butanetriol, 1,2,3-pentanetriol, 2-methyl-1,2,3-propanetriol, 2-methyl-2,3,4-butanetriol, 2-ethyl-1,2,3-butanetriol, 2,3,4-pentanetriol, 2,3,4-hexanetriol, 4-
  • the active hydrogen-containing compound is preferably a polyhydric alcohol containing an alkylene group having 3 or more carbon atoms, and particularly preferably a polyhydric alcohol containing an alkylene group having 3 or 4 carbon atoms.
  • dihydric alcohols are particularly preferable in view of the smoothness and distinctness of image of the resulting multilayer coating film.
  • ethylene glycol, diethylene glycol, trimethylene glycol, propylene glycol, and 1,4-butanediol are preferable, and trimethylene glycol, propylene glycol, and 1,4-butanediol are particularly preferable.
  • the polyoxyalkylene-containing polyols (C1) can be typically obtained by performing an addition reaction of an alkylene oxide to the active hydrogen-containing compound in the presence of an alkali catalyst at a temperature of 60 to 160° C. at ordinary pressure or under increased pressure by a usual method.
  • alkylene oxides include ethylene oxide, propylene oxide, butylene oxide, and like alkylene oxides.
  • propylene oxide and butylene oxide can be preferably used, and propylene oxide can be particularly preferably used. These may be used singly or in a combination of two or more. If two or more of them are used in combination, the addition may be performed blockwise or randomly.
  • polyoxyalkylene-containing polyols (C1) polyoxyalkylene glycols can be preferably used.
  • polyoxyalkylene glycols commercially available products are usable. Examples thereof include, as polyethylene glycol, #300, #400, and #600 (all produced by Dai-ichi Kogyo Seiyaku Co., Ltd.); as polypropylene glycol, Hyprox MP-600 (produced by Dainippon Ink and Chemicals), Primepol PX-1000, Sannix SP-750, Sannix PP-400, Sannix PP-600, and Sannix PP-1000 (all produced by Sanyo Chemical Industries, Ltd.), Diol-400, Diol-700, and Diol-1000 (all produced by Mitsui Chemicals, Inc.); as polytetramethylene glycol, PTMG-650, PTMG-850, and PTMG-1000 (all produced by Mitsubishi Chemical Corporation); and the like.
  • Examples of usable polycarbonate polyols (C2) include commonly used compounds having 1,6-hexanediol as a basic skeleton, and polycarbonate polyols produced by known methods. Examples thereof include polycarbonate polyols obtained by reacting a carbonate component, such as alkylene carbonate, diaryl carbonate, or dialkyl carbonate, or phosgene with the aliphatic polyol component described below.
  • a carbonate component such as alkylene carbonate, diaryl carbonate, or dialkyl carbonate, or phosgene
  • Examples of the aliphatic polyol component include 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, and like linear glycols; 1,2-propanediol, neopentyl glycol, 3-methyl-1,5-pentanediol, ethylbutylpropanediol, and like branched glycols; diethylene glycol, triethylene glycol, and like ether diols.
  • the polycarbonate polyols (C2) are preferably those that have no ring structures, such as an aromatic ring or an aliphatic ring, in their molecular structure, from the viewpoint of thermal flowability during heat-curing.
  • polycarbonate polyols commercially available products are usable. Examples thereof include UH-50, UH-100, and UM-90 (1 ⁇ 3) (all produced by Ube Industries, Ltd.); C-1100 and C-XP-2716 (both produced by Bayer); and the like.
  • the polyol (C) is used in an amount of preferably 1 to 20 mass %, particularly preferably 2 to 10 mass %, and further particularly preferably 3 to 7 mass % based on the total solids content of the carboxy-containing compound (A) and the polyepoxide (B).
  • polyol (C) in the above-mentioned ranges improves thermal flowability in the curing process for a multilayer coating film, thus enabling sufficient concealment of the surface state (irreguralities) of a substrate. This suppresses the influence of the surface state of a substrate, thereby obtaining a multilayer coating film with excellent finished appearance in terms of smoothness and distinctness of image, as well as excellent coating film performance in terms of weatherability, etc.
  • the present coating composition may comprise a curing catalyst, if necessary.
  • a curing catalyst examples include those that are effective for the ring-opening esterification reaction between carboxy groups in the carboxy-containing compound (A) and epoxy groups in the polyepoxide (B).
  • Examples include tetraethylammonium bromide, tetrabutylammonium bromide, tetraethylammonium chloride, tetrabutylphosphonium bromide, triphenylbenzylphosphonium chloride, and like quaternary salt catalysts; mixtures of substantially equivalent amounts of a quaternary salt and an acidic phosphoric acid compound, such as dibutyl phosphoric acid; triethylamine, tributylamine, and like amine compounds; and the like.
  • quaternary salt catalysts and mixtures of substantially equivalent amounts of a quaternary salt and an acidic phosphoric acid compound, such as dibutyl phosphoric acid are preferable.
  • Mixtures of substantially equivalent amounts of a quaternary salt and an acidic phosphoric acid compound, such as dibutyl phosphoric acid, are particularly preferable, because such mixtures improve the storage stability of the coating composition and prevent the decrease in spray coating suitability caused by the reduction in the electrical resistance of the coating composition, while retaining the catalytic action.
  • the amount of the curing catalyst be typically about 0.01 to about 5 mass % based on the total solids content of the carboxy-containing compound (A) and the polyepoxide (B).
  • the present coating composition may comprise, if necessary, a color pigment, an effect pigment, a dye, etc., in such amounts that the transparency of the coating composition is not impaired, and may further comprise an extender pigment, a UV absorber, an antifoaming agent, a thickener, an anticorrosive, a surface control agent, an organic solvent, etc.
  • the present coating composition generally has a solids concentration of preferably 45 to 60 mass %, more preferably 50 to 60 mass %, and even more preferably 50 to 55 mass %.
  • the total concentration of the carboxy-containing compound (A) and the polyepoxide (B) in the coating composition is generally preferably 30 to 58 mass %, and more preferably 40 to 58 mass %.
  • the present coating composition may be applied by a known method, such as airless spray coating, air spray coating, or rotary atomization coating.
  • An electrostatic charge may be applied during coating. It is usually preferable that the coating film thickness be 10 to 60 ⁇ m, and more preferably 25 to 50 ⁇ m, when cured.
  • the substrate to which an aqueous first colored coating composition (X) can be applied according to the present invention is not particularly limited.
  • substrates include exterior panel parts of automotive bodies, such as passenger cars, trucks, motorcycles, and buses; automotive components; exterior panel parts of household electrical appliances, such as cellular phones and audiovisual apparatus; and the like.
  • exterior panel parts of automotive bodies and automotive components are preferable.
  • the materials for such substrates are not particularly limited. Examples thereof include metallic materials, such as iron, aluminum, brass, copper, tin plate, stainless steel, galvanized steel, and steel plated with zinc alloy (Zn—Al, Zn—Ni, Zn—Fe, etc.); plastic materials, such as polyethylene resin, polypropylene resin, acrylonitrile-butadiene-styrene (ABS) resin, polyamide resin, acrylic resin, vinylidene chloride resin, polycarbonate resin, polyurethane resin, epoxy resin, and like resins, and various types of FRP; inorganic materials, such as glass, cement, and concrete; wood; textile materials, such as paper and cloth; and the like. Among these, metallic materials and plastic materials are preferable.
  • metallic materials such as iron, aluminum, brass, copper, tin plate, stainless steel, galvanized steel, and steel plated with zinc alloy (Zn—Al, Zn—Ni, Zn—Fe, etc.
  • plastic materials such as polyethylene resin,
  • the substrate may be a metallic material as described above or one formed therefrom, such as a vehicle body, whose metallic surface has been subjected to a surface treatment, such as phosphate treatment, chromate treatment, or composite oxide treatment. Further, the substrate may also be a metallic material, vehicle body, or the like as described above, on which an undercoating film of various electrodeposition coating compositions has been formed. Among these, vehicle bodies on which an undercoating film has been formed using a cationic electrodeposition coating composition are particularly preferable.
  • an aqueous first colored coating composition (X) is applied to a substrate to form a first colored coating film.
  • the aqueous first colored coating composition (X) that is applied to the substrate may be an aqueous liquid coating composition comprising a thermosetting resin component and water, and comprising, if necessary, an organic solvent, a color pigment, an extender pigment, an effect pigment, a surface control agent, an antisettling agent, etc.
  • aqueous coating compositions refer to coating compositions that contain water as a main component of the solvent.
  • the thermosetting resin component may be a known coating resin composition comprising a base resin (I) and a crosslinking agent (II).
  • a base resin (I) examples include polyester resins, acrylic resins, vinyl resins, alkyd resins, and urethane resins. Such base resins have crosslinkable functional groups such as hydroxy and hydrophilic functional groups such as carboxy.
  • the crosslinking agent (II) examples include melamine resins and blocked or unblocked polyisocyanate compounds.
  • a hydroxy-containing acrylic resin (I-1) and/or a hydroxy-containing polyester resin (I-2) as the base resin (I)
  • an amino resin (II-1) and/or a blocked polyisocyanate compound (II-2) as the crosslinking agent (II).
  • the hydroxy-containing acrylic resin (I-1) can be produced by, for example, (co)polymerizing at least one unsaturated monomer component containing a hydroxy-containing unsaturated monomer and further containing, optionally, one or more other unsaturated monomers copolymerizable with the hydroxy-containing unsaturated monomer, under usual conditions.
  • the hydroxy-containing unsaturated monomer is a compound having at least one hydroxy group and at least one polymerizable unsaturated bond per molecule.
  • examples thereof include monoesterified products of (meth)acrylic acid with a dihydric alcohol having 2 to 8 carbon atoms, such as 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl(meth)acrylate, 3-hydroxypropyl(meth)acrylate, and 4-hydroxybutyl(meth)acrylate; ⁇ -caprolactone-modified products of monoesterified products of (meth)acrylic acid with a dihydric alcohol having 2 to 8 carbon atoms; allyl alcohol; (meth)acrylates having hydroxy-terminated polyoxyethylene chains; and the like.
  • Examples of other unsaturated monomers copolymerizable with the hydroxy-containing unsaturated monomer include alkyl or cycloalkyl (meth)acrylate, such as methyl (meth)acrylate, ethyl (meth)acrylate, n-propyl(meth)acrylate, 1-propyl(meth)acrylate, n-butyl (meth)acrylate, i-butyl (meth)acrylate, tert-butyl (meth)acrylate, n-hexyl(meth)acrylate, octyl (meth)acrylate, 2-ethylhexyl(meth)acrylate, nonyl (meth)acrylate, lauryl (meth)acrylate, tridecyl (meth)acrylate, stearyl (meth)acrylate, “Isostearyl Acrylate” (trade name, produced by Osaka Organic Chemical Industry Ltd.), cyclohexyl (meth)acryl
  • the hydroxy-containing acrylic resin (I-1) may have a hydroxy value of typically 1 to 200 mg KOH/g, preferably 2 to 100 mg KOH/g, and even more preferably 3 to 60 mg KOH/g, and an acid value of typically 1 to 200 mg KOH/g, preferably 2 to 150 mg KOH/g, and more preferably 5 to 100 mg KOH/g.
  • the hydroxy-containing acrylic resin (I-1) may have a weight average molecular weight of typically 1,000 to 5,000,000, preferably 2,000 to 3,000,000, and more preferably 3,000 to 1,000,000.
  • the amount of the hydroxy-containing acrylic resin (I-1) can be typically 0 to 90 mass %, preferably 5 to 60 mass %, and more preferably 10 to 40 mass %, based on the total solids content of the base resin (I) and the crosslinking agent (II) (hereafter, referred to collectively as resin component) in the aqueous first colored coating composition (X).
  • the hydroxy-containing polyester resin (I-2) can be produced by, for example, an esterification reaction or transesterification reaction of a polybasic acid component with a polyhydric alcohol component. More specifically, for example, the hydroxy-containing polyester resin (I-2) can be produced by performing an esterification reaction under such conditions that the equivalent ratio of carboxy groups in the polybasic acid component to hydroxy groups in the polyhydric alcohol (COOH/OH) is less than 1, i.e., in a state where more hydroxy groups are present than carboxy groups.
  • the polybasic acid component is a compound having at least two carboxy groups per molecule.
  • examples thereof include polybasic acids, such as phthalic acid, isophthalic acid, terephthalic acid, succinic acid, glutaric acid, adipic acid, azelaic acid, sebacic acid, tetrahydrophthalic acid, hexahydrophthalic acid, maleic acid, fumaric acid, itaconic acid, trimellitic acid, and pyromellitic acid; anhydrides of these polybasic acids; lower alkyl esters of these polybasic acids; and the like. These may be used singly or in a combination of two or more.
  • the polyhydric alcohol component is a compound having at least two hydroxy groups per molecule.
  • examples thereof include ⁇ -glycols, such as ethylene glycol, 1,2-propylene glycol, 1,2-butylene glycol, 2,3-butylene glycol, 1,2-hexanediol, 1,2-dihydroxycyclohexane, 3-ethoxypropane-1,2-diol, and 3-phenoxypropane-1,2-diol; neopentyl glycol, 2-methyl-1,3-propanediol, 2-methyl-2,4-pentanediol, 3-methyl-1,3-butanediol, 2-ethyl-1,3-hexanediol, 2,2-diethyl-1,3-propanediol, 2,2,4-trimethyl-1,3-pentanediol, 2-butyl-2-ethyl-1,3-propanediol, 2-phenoxypropan
  • the esterification or transesterification reaction of the polybasic acid component with the polyhydric alcohol component can be performed by a known method, for example, by polycondensation of the polybasic acid component with the polyhydric alcohol component at a temperature of about 180 to about 250° C.
  • the hydroxy-containing polyester resin (I-2) can be modified with a fatty acid, a monoepoxy compound, or the like, during the preparation of the polyester resin or after the esterification reaction, if necessary.
  • fatty acids include coconut oil fatty acid, cottonseed oil fatty acid, hempseed oil fatty acid, rice bran oil fatty acid, fish oil fatty acid, tall oil fatty acid, soybean oil fatty acid, linseed oil fatty acid, tung oil fatty acid, rapeseed oil fatty acid, castor oil fatty acid, dehydrated castor oil fatty acid, safflower oil fatty acid, and the like.
  • monoepoxy compounds include “Cardura E10P” (trade name, produced by HEXION Specialty Chemicals; glycidyl ester of a synthetic highly branched saturated fatty acid), and the like.
  • the hydroxy-containing polyester resin (I-2) may have a hydroxy value of typically 10 to 300 mg KOH/g, preferably 25 to 250 mg KOH/g, and more preferably 50 to 200 mg KOH/g, and an acid value of typically 1 to 200 mg KOH/g, preferably 5 to 100 mg KOH/g, and more preferably 10 to 60 mg KOH/g.
  • the hydroxy-containing polyester resin (I-2) may have a weight average molecular weight of typically 500 to 50,000, preferably 1,000 to 40,000, and more preferably 1,500 to 30,000.
  • the amount of the hydroxy-containing polyester resin (I-2) can be generally 0 to 90 mass %, preferably 10 to 60 mass %, and more preferably 15 to 50 mass %, based on the total solids content of the resin component in the aqueous first colored coating composition (X).
  • hydroxy-containing acrylic resin (I-1) and hydroxy-containing polyester resin (I-2) it is preferable that some or all of the carboxy groups that may be contained therein be neutralized with a basic compound, to facilitate dissolution or dispersion thereof in water.
  • Examples of basic compounds include hydroxides of alkali metals or alkaline earth metals, such as sodium hydroxide, potassium hydroxide, lithium hydroxide, calcium hydroxide, and barium hydroxide; ammonia; primary monoamines, such as ethylamine, propylamine, butylamine, benzylamine, monoethanolamine, neopentanolamine, 2-aminopropanol, 2-amino-2-methyl-1-propanol, and 3-aminopropanol; secondary monoamines, such as diethylamine, diethanolamine, di-n-propanolamine, diisopropanolamine, N-methylethanolamine, and N-ethylethanolamine; tertiary monoamines, such as dimethylethanolamine, trimethylamine, triethylamine, triisopropylamine, methyldiethanolamine, and 2-(dimethylamino)ethanol; polyamines, such as diethylenetriamine, hydroxyethy
  • urethane resins include, in addition to general urethane resins, those in which polyisocyanate compounds are extended to higher molecular weight by urethanization reactions with some of the hydroxy groups in the hydroxy-containing acrylic resin (I-1) and the hydroxy-containing polyester resin (I-2).
  • Examples of the amino resin (II-1) include partially or fully methylolated amino resins obtained by reacting amino components with aldehydes.
  • Examples of amino components include melamine, urea, benzoguanamine, acetoguanamine, steroguanamine, spiroguanamine, dicyandiamide, and the like.
  • Examples of aldehydes include formaldehyde, paraformaldehyde, acetaldehyde, benzaldehyde, and the like. Those obtained by partially or fully etherifying the partially or fully methylolated amino resins with alcohols are also usable.
  • alcohols used for etherification include methyl alcohol, ethyl alcohol, n-propyl alcohol, i-propyl alcohol, n-butyl alcohol, i-butyl alcohol, 2-ethylbutanol, 2-ethylhexanol, and the like.
  • the amino resin (II-1) is preferably a melamine resin.
  • a methyl-etherified melamine resin obtained by etherifying some or all of the methylol groups of a partially or fully methylolated melamine resin with methyl alcohol a butyl-etherified melamine resin obtained by etherifying some or all of the methylol groups of a partially or fully methylolated melamine resin with butyl alcohol
  • like alkyl-etherified melamine resins are preferable.
  • the melamine resin has a weight average molecular weight of typically 500 to 5,000, more preferably 600 to 4,000, and even more preferably 700 to 3,000.
  • sulfonic acids such as p-toluenesulfonic acid, dodecylbenzenesulfonic acid, and dinonylnaphthalene sulfonic acid, and salts of these acids with amine may be used as a catalyst.
  • the blocked polyisocyanate compound (II-2) is a polyisocyanate compound having at least two isocyanate groups per molecule, and is obtained by blocking isocyanate groups of the polyisocyanate compound with a blocking agent, such as an oxime, a phenol, an alcohol, an active methylene compound, a lactam, or a mercaptan.
  • a blocking agent such as an oxime, a phenol, an alcohol, an active methylene compound, a lactam, or a mercaptan.
  • the ratio of the base resin (I) and the crosslinking agent (II) is preferably such that based on the total solids content of the base resin (I) and the crosslinking agent (II), the proportion of the base resin (I) is typically 40 to 90 mass %, and particularly 50 to 80 mass %, and the proportion of the crosslinking agent (II) is typically 60 to 10 mass %, and particularly 50 to 20 mass %.
  • color pigments include titanium oxide, zinc oxide, carbon black, lead sulfate, calcium plumbate, zinc phosphate, aluminum phosphate, zinc molybdate, calcium molybdate, berlin blue, ultramarine blue, cobalt blue, copper phthalocyanine blue, indanthrone blue, chrome yellow, synthetic yellow iron oxide, transparent iron oxide red (yellow), bismuth vanadate, titanium yellow, zinc yellow, monoazo yellow, isoindolinone yellow, metallic complex azo yellow, quinophthalone yellow, benzimidazolone yellow, iron oxide red, minium, monoazo red, quinacridone red, azo-lake (Mn salt), quinacridone magenta, anthanthrone orange, dianthraquinonyl red, perylene maroon, quinacridone magenta, perylene red, diketo pyrrolo-pyrrole chrome vermilion, chlorination phthalocyanine green, bromination phthalocyanine green, pyrazolone orange
  • the amount of the color pigment is typically 1 to 120 mass %, preferably 10 to 100 mass %, and more preferably 15 to 90 mass %, based on the total solids content of the resin component in the aqueous first colored coating composition (X).
  • extender pigments examples include clay, kaolin, barium sulfate, barium carbonate, calcium carbonate, talc, silica, alumina white, and the like. Of these, barium sulfate and/or talc is preferably used.
  • the amount of the extender pigment is typically 1 to 100 mass %, preferably 5 to 60 mass, and more preferably 8 to 40 mass %, based on the total solids content of the resin component in the aqueous first colored coating composition (X).
  • effect pigments include non-leafing or leafing aluminum (including vapor-deposited aluminum), copper, zinc, brass, nickel, aluminum oxide, mica, titanium oxide- or iron oxide-coated aluminum oxide, titanium oxide- or iron oxide-coated mica, glass flakes, holographic pigments, and the like. These may be used singly or in a combination of two or more.
  • the amount of the effect pigment is typically 1 to 50 mass %, preferably 2 to 30 mass %, and more preferably 3 to 20 mass %, based on the total solids content of the resin component in the aqueous first colored coating composition (X).
  • the aqueous first colored coating composition (X) can be applied to the substrate by a known method, such as air spray coating, airless spray coating, or rotary atomization coating.
  • An electrostatic charge may be applied during the coating. It is usually preferable that the coating film thickness be 10 to 100 ⁇ m, more preferably 10 to 50 ⁇ m, and even more preferably 15 to 35 ⁇ m, when cured.
  • An aqueous second colored coating composition (Y) is then applied to the first colored coating film formed using the aqueous first colored coating composition in step (1).
  • the aqueous second colored coating composition (Y) used in the present invention may be an aqueous liquid coating composition comprising a thermosetting resin component and water, and comprises, if necessary, an organic solvent, a color pigment, an extender pigment, an effect pigment, a surface control agent, an antisettling agent, etc.
  • the thermosetting resin component may be a known coating resin composition as mentioned in the description of the aqueous first colored coating composition (X), i.e., a coating resin composition comprising a base resin (I) and a crosslinking agent (II).
  • a coating resin composition comprising a base resin (I) and a crosslinking agent (II).
  • the base resin (I) include polyester resins, acrylic resins, vinyl resins, alkyd resins, and urethane resins.
  • Such base resins have crosslinkable functional groups, such as hydroxy, and hydrophilic functional groups, such as carboxy.
  • the crosslinking agent (II) include melamine resins and blocked or unblocked polyisocyanate compounds.
  • the aqueous second colored coating composition (Y) may further contain pigments as described above, such as color pigments, extender pigments, and effect pigments; and additives generally used for coating compositions, such as curing catalysts, UV absorbers, light stabilizers, antifoaming agents, plasticizers, organic solvents, surface control agents, and antisettling agents. These may be used singly, or in a combination of two or more.
  • an effect pigment as at least a part of the pigment component in the aqueous second colored coating composition (Y) makes it possible to form a metallic tone or pearlescent tone coating film having a delicate appearance, and thus is preferable.
  • the aqueous second colored coating composition (Y) can be applied by a known method, such as air spray coating, airless spray coating, or rotary atomization coating.
  • An electrostatic charge may be applied during the coating. It is usually preferable that the coating film thickness be 5 to 40 ⁇ m, and more preferably 10 to 30 ⁇ m when cured.
  • the first colored coating film formed using the aqueous first colored coating composition (X) in step (1) is adjusted to have a solids content of preferably 70 to 100 mass %, particularly preferably 75 to 99 mass %, and further particularly preferably 80 to 98 mass %.
  • the solids content can be adjusted by preliminary heating (preheating), air-blowing, or other methods.
  • the preheating temperature is room temperature to about 100° C., preferably about 40 to about 90° C., and more preferably about 60 to about 80° C.
  • the preheating time is about 30 seconds to about 15 minutes, preferably about 1 to about 10 minutes, and more preferably about 3 to about 5 minutes.
  • a clear coating composition (Z) is then applied to the second colored coating film formed using the aqueous second colored coating composition in step (2).
  • the coating composition (present coating composition) of the present invention is applied as the clear coating composition (Z).
  • the clear coating composition (Z) can be applied by a known method, such as airless spray coating, air spray coating, or rotary atomization coating.
  • An electrostatic charge may be applied during the coating. It is usually preferable that the coating film thickness be 10 to 60 ⁇ m, and more preferably 25 to 50 ⁇ m, when cured.
  • the second colored coating film formed using the aqueous second colored coating composition (Y) in step (2) is adjusted to have a solids content of preferably 70 to 100 mass %, particularly preferably 75 to 99 mass %, and further particularly preferably 80 to 98 mass %.
  • the three layers, i.e., the first colored coating film, the second colored coating film, and the clear coating film, of the multilayer coating film formed as described above can be cured all at once by heating at a temperature of typically about 80 to about 170° C., and preferably about 120 to about 160° C., for typically about 10 to about 60 minutes, and preferably about 20 to about 40 minutes, using a usual coating-film-heat-curing method, such as hot-air heating, infrared heating, or high-frequency heating.
  • a usual coating-film-heat-curing method such as hot-air heating, infrared heating, or high-frequency heating.
  • the remaining monomer emulsion was then added dropwise to the reactor over a period of 3 hours while the temperature of the reactor was maintained. After completion of the dropwise addition, the mixture was aged for 1 hour. Then, while 40 parts of a 5% 2-(dimethylamino)ethanol aqueous solution was gradually added to the reactor, the mixture was cooled to 30° C., and filtered through a 100-mesh nylon cloth to obtain a hydroxy-containing acrylic resin emulsion (I-1-1) having a solids concentration of 45%.
  • the obtained hydroxy-containing acrylic resin had an acid value of 12 mg KOH/g, and a hydroxy value of 43 mg KOH/g.
  • Monomer emulsion 50 parts of deionized water, 10 parts of styrene, 40 parts of methyl methacrylate, 35 parts of ethyl acrylate, 3.5 parts of n-butyl methacrylate, 10 parts of 2-hydroxyethyl methacrylate, 1.5 parts of acrylic acid, 1.0 part of Aqualon KH-10, and 0.03 parts of ammonium persulfate were mixed by stirring to obtain a monomer emulsion.
  • the monomer emulsion (2) described below was then added dropwise over a period of 1 hour, and the mixture was aged for 1 hour, after which, while 40 parts of a 5% dimethylethanolamine aqueous solution was gradually added to the reactor, the mixture was cooled to 30° C., and filtered through a 100-mesh nylon cloth to obtain a hydroxy-containing acrylic resin emulsion (I-1-2) having an average particle size of 100 nm (as measured with a “COULTER N4” submicron particle size distribution analyzer (trade name, produced by Beckman Coulter, Inc.) at 20° C. in a state diluted with deionized water), and a solids concentration of 30%.
  • the obtained hydroxy-containing acrylic resin had an acid value of 33 mg KOH/g, and a hydroxy value of 25 mg KOH/g.
  • Monomer emulsion (1) 42 parts of deionized water, 0.72 parts of Aqualon KH-10, 2.1 parts of methylenebisacrylamide, 2.8 parts of styrene, 16.1 parts of methyl methacrylate, 28 parts of ethyl acrylate, and 21 parts of n-butyl acrylate were mixed by stirring to obtain a monomer emulsion (1).
  • Monomer emulsion (2) 18 parts of deionized water, 0.31 parts of Aqualon KH-10, 0.03 parts of ammonium persulfate, 5.1 parts of methacrylic acid, 5.1 parts of 2-hydroxyethyl acrylate, 3 parts of styrene, 6 parts of methyl methacrylate, 1.8 parts of ethyl acrylate, and 9 parts of n-butyl acrylate were mixed by stirring to obtain a monomer emulsion (2).
  • hydroxy-containing polyester resin solution (I-2-1) having a solids concentration of 45% and a pH of 7.2.
  • the obtained hydroxy-containing polyester resin had an acid value of 35 mg KOH/g and a hydroxy value of 128 mg KOH/g, and a weight average molecular weight of 13,000.
  • the reaction product was then diluted with 1-octanol (alcohol solvent having a boiling point of 195° C.) to obtain a hydroxy-containing polyester resin solution (I-2-2) having a solids concentration of 70%.
  • the obtained hydroxy-containing polyester resin had an acid value of 46 mg KOH/g, a hydroxy value of 150 mg KOH/g, and a weight average molecular weight of 6,400.
  • aqueous first colored coating composition (X-1) having a pH of 8.0, a coating composition solids content of 48%, and a viscosity of 30 seconds as measured with Ford cup No. 4 at 20° C.
  • An aqueous first colored coating composition (X-2) was obtained in the same manner as in Production Example 5, except that 28.6 parts of U-COAT UX-8100 and 5 parts of Sannix PP-1000 (trade name, produced by Sanyo Chemical Industries, Ltd., polyoxypropylene glycol, number average molecular weight: 1,000, active ingredient: 100%) were used instead of 43 parts of U-COAT UX-8100.
  • Phosphoric acid group-containing resin solution A mixed solvent of 27.5 parts of methoxypropanol and 27.5 parts of isobutanol was placed in a reactor equipped with a thermometer, a thermostat, a stirrer, a reflux condenser, and a dropping funnel, and heated to 110° C.
  • a mixture comprising 0.5 parts of t-butylperoxyoctanoate and 20 parts of isopropanol was added dropwise for 1 hour. The mixture was then stirred and aged for 1 hour to obtain a phosphoric acid group-containing resin solution having a solids concentration of 50%.
  • the resin had an acid value attributable to the phosphoric acid groups of 83 mg KOH/g, a hydroxy value of 29 mg KOH/g, and a weight average molecular weight of 10,000.
  • aqueous second colored coating composition (Y-1) having a pH of 8.0, a coating composition solids content of 25%, and a viscosity of 40 seconds as measured with Ford cup No. 4 at 20° C.
  • Monomer mixture 500 parts of styrene, 500 parts of n-butyl methacrylate, 500 parts of isobutyl methacrylate, 500 parts of maleic anhydride, 1,000 parts of 2-ethoxyethyl propionate, and 100 parts of p-tert-butyl peroxy-2-ethylhexanoate were mixed by stirring to obtained a monomer mixture.
  • 410 parts of xylene and 77 parts of n-butanol were placed in a reactor equipped with a thermometer, a thermostat, a stirrer, a reflux condenser, a nitrogen gas inlet tube, and a dropping funnel, and heated to 125° C. while nitrogen gas was supplied. After the temperature reached 125° C., the nitrogen gas flow was stopped, and monomer mixture 1 described below was added dropwise at a constant rate over a period of 4 hours. Note that azobisisobutyronitrile is a polymerization initiator.
  • Monomer mixture 1 432 parts (30%) of glycidyl methacrylate, 576 parts (40%) of n-butyl acrylate, 144 parts (10%) of styrene, 288 parts (20%) of 2-hydroxyethyl methacrylate, and 72 parts of azobisisobutyronitrile were mixed by stirring to obtain a monomer mixture.
  • aging was carried out at 125° C. for 30 minutes while nitrogen gas was supplied, and further, a mixture of 90 parts of xylene, 40 parts of n-butanol, and 14.4 parts of azobisisobutyronitrile was then added dropwise over a period of 2 hours. Thereafter, the mixture was aged for 2 hours to obtain a polyepoxide (B-1) solution having a solids content of 70%.
  • the obtained polyepoxide (B-1) had a number average molecular weight of 2,000, an epoxy group content of 2.12 mmol/g, and a hydroxy value of 86 mg KOH/g.
  • a polyepoxide (B-2) solution having a solids content of 70% was obtained in the same manner as in Production Example 10, except that monomer mixture 2 described below was used instead of monomer mixture 1.
  • the obtained polyepoxide (B-2) had a number average molecular weight of 2,000, an epoxy group content of 2.12 mmol/g, and a hydroxy value of 130 mg KOH/g.
  • Monomer mixture 2 432 parts (30%) of glycidyl methacrylate, 432 parts (30%) of n-butyl acrylate, 144 parts (10%) of styrene, 432 parts (30%) of 2-hydroxyethyl methacrylate, 72 parts of azobisisobutyronitrile were mixed by stirring to obtain a monomer mixture.
  • Production of Clear Coating Composition (Z) 432 parts (30%) of glycidyl methacrylate, 432 parts (30%) of n-butyl acrylate, 144 parts (10%) of styrene, 432 parts (30%) of 2-hydroxyethyl methacrylate, 72 parts of azobisisobutyronitrile were mixed by stirring to obtain a monomer mixture.
  • ETERNACOLL UH-50 trade name, produced by Ube Industries, Ltd., 1,6-hexanediol-based polycarbonate diol, number average molecular weight: 500, active ingredient: 100%
  • ETERNACOLL UH-200 trade name, produced by Ube Industries, Ltd., 1,6-hexanediol-based polycarbonate diol, number average molecular weight: 2,000, active ingredient: 100%
  • test plates were prepared and evaluation tests were performed in the manner described below.
  • Electron GT-10 (trade name, produced by Kansai Paint Co., Ltd., cationic electrodeposition coating composition) was applied to a cold-rolled steel plate treated with zinc phosphate by electrodeposition to a film thickness of 20 ⁇ m (when dried), and cured by heating at 170° C. for 30 minutes to prepare test substrate 1.
  • Test substrate 1 had a surface roughness Ra of 0.21.
  • test substrate 2 that had a surface roughness larger than that of test substrate 1 was prepared.
  • Test substrate 2 had a surface roughness Ra of 0.38.
  • the aqueous first colored coating composition (X-1) obtained in Production Example 5 was electrostatically applied to test substrate 1 to a film thickness of 25 ⁇ m (when dried) using a rotary atomizing electrostatic coating apparatus. The resulting substrate was allowed to stand for 2 minutes, followed by preheating at 80° C. for 3 minutes.
  • the aqueous second colored coating composition (Y-1) obtained in Production Example 8 was electrostatically applied to the uncured first colored coating film to a film thickness of 15 ⁇ m (when dried) using a rotary atomizing electrostatic coating apparatus.
  • the resulting substrate was allowed to stand for 2 minutes, followed by preheating at 80° C. for 3 minutes.
  • the clear coating composition (Z-1) obtained in Production Example 12 was electrostatically applied to the second colored coating film to a film thickness of 35 ⁇ m (when dried).
  • the resulting substrate was allowed to stand for 7 minutes, and then heated at 140° C. for 20 minutes (retention time) to cure the first colored coating film, the second colored coating film, and the clear coating film, thereby preparing a test plate.
  • Test plates were prepared in the same manner as in Example 1, except that test substrate 1 or 2 shown in Table 1 was used as a test substrate, the aqueous first colored coating composition (X-1) or (X-2) shown in Table 1 was used as an aqueous first colored coating composition (X), and any of the clear coating compositions (Z-1) to (Z-14) shown in Table 1 was used as a clear coating composition (Z).
  • test plates obtained in Examples 1 to 11 and Comparative Examples 1 to 6 were evaluated by the test methods described below. Table 1 shows the evaluation results.
  • Smoothness evaluated based on a Wc value measured using Wave Scan DOI (trade name, produced by BYK Gardner).
  • the Wc value is an index of the amplitude of surface roughness at a wavelength of about 1 to about 3 mm. A smaller Wc value indicates a higher smoothness of the coated surface.
  • Distinctness of image evaluated based on a Wa value measured using Wave Scan DOI.
  • the Wa value is an index of the amplitude of surface roughness at a wavelength of about 0.1 to about 0.3 mm. A smaller Wa value indicates a higher distinctness of image of the coated surface.
  • Accelerated weathering resistance a cycle test that combines irradiation and rainfall conditions was performed under the test conditions described in JIS K5600-7-7 (method 1), using the Super Xenon Weather Meter (trade name, accelerated weathering tester, produced by Suga Test Instruments Co., Ltd.) (specimen wetting cycle: 18 minutes/2 hours, black panel temperature: 61 to 65° C.) After a total of 3,000 hours of the cycle test time, each test plate was immersed in warm water at 40° C. for 2 days, and the adhesion of the coating film was then evaluated.
  • Adhesion was evaluated by forming a grid of 100 squares (2 mm ⁇ 2 mm) on the coating film of each test plate in accordance with JIS K 5600-5-6 (1990), applying adhesive tape to the surface of the grid portion, peeling the tape off rapidly, and then checking the number of coating film squares remaining. 98 or more squares of the coating film remaining is regarded as an acceptable level.

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